Disposable garment having improved fitness to body during use

ABSTRACT

A disposable garment comprising a chassis having a front region, a back region, and a crotch region between the front and back regions, the chassis comprising a liquid impervious backsheet and at least one pair of side panels extending laterally outwardly from the chassis. The backsheet comprises a liquid impervious film extending longitudinally in the front, back, and crotch regions, and having a nonuniform lateral width so as to form a first portion in the crotch region and a second portion in the front or back region. The second portion has a lateral width dimension less than the lateral width dimension of the first portion such that the film does not extend into the side panels. At least one of the side panels comprises an elastomeric material extending laterally outwardly from the chassis, wherein the elastomeric material is joined to the second portion of the liquid impervious film.

FIELD

The present invention relates to disposable garments. Examples of suchdisposable garments include disposable underwear, disposable diapersincluding pull-on diapers and training pants, and disposable panties formenstrual use. More specifically, the present invention relates todisposable garments which have improved fitness to body during use.

BACKGROUND

Infants and other incontinent individuals wear disposable garments suchas diapers to receive and contain urine and other body exudes. One typeof the disposable garments, which is often called as “tape type”, has afastener system to hold the disposable garment at the wearer's waistarea. As the fastener system, either an adhesive tape system or amechanical fastener system is often used. Recently, elasticallystretchable side panels are preferably used in this type of thedisposable garments, because they can provide a better fit to thewearer's waist area by jointly working with the fastener system. Anothertype of absorbent garments, which is often called as “pant type” or“pull-on”, has fixed sides has become popular for use on children ableto walk and often who are toilet training. The pull-on garments haveside panels which edges are seamed together to form two leg openings anda waist opening. These pull-on garments need to fit snugly about thewaist and legs of the wearer without drooping, sagging or sliding downfrom its position on the torso to contain body exudes. Examples of thesepull-on garments are disclosed, for example, in U.S. Pat No. 5,171,239to lgaue et al., U.S. Pat No. 4,610,681 to Strohbeen et al., WO 93/17648published on Sep. 16, 1993, U.S. Pat No. 4,940,464 to Van Gompel et al.,U.S. Pat. No. 5,246,433 to Hasse et al., and U.S. Pat No. 5,569,234 toBuell et al.

These disposable garments have stretch laminates in the side panels toprovide a better fitness of the garments on the wearer. The stretchlaminates usually have an elastic material which has important factorsfor the fitness of disposable garments. More specifically, the extensionproperties including the extension forces, recovery forces, retentionforces, and available stretch (extension) of the elastic material areimportant considerations in the performance of the fitness during use.They also effect the ability of the applicator to achieve a suitabledegree of application stretch for pull-on garments.

In the meantime, disposable garments typically have a liquid imperviousbacksheet to prevent absorbed liquid from passing through the garmentand soiling adjacent articles such as clothing, bedding and the like. Itis generally expected that the liquid impervious backsheet is flexibleenough to be compliant and readily conformable to the general shape ofthe human body. However, depending on the structural relationshipbetween the liquid impervious backsheet and the elastic material used inthe side panels, the elastic material can not fully provide expectedproperties, resulting in loss of the performance of the fitness ofdisposable garments during use. Thus, none of the existing art providesall of the advantages and benefits of the present invention.

SUMMARY

The present invention is directed to a disposable garment, comprising achassis having a longitudinal centerline, a front region, a back regionand a crotch region between the front region and the back region, thechassis comprising a liquid pervious topsheet, a liquid imperviousbacksheet associated with the topsheet, and an absorbent core disposedbetween the topsheet and the backsheet; and at least one pair of sidepanels extending laterally outwardly from the chassis in the front orback region. The backsheet comprises a nonwoven outer cover and a liquidimpervious film joined to the outer cover. The liquid impervious filmlongitudinally extends in the front, back and crotch regions, and has anonuniform lateral width so as to form a first portion in at least aportion of the crotch region, and a second portion in at least a portionof the front or back region. The second portion has a lateral widthdimension less than the lateral width dimension of the first portionsuch that the film does not extend into the at least one pair of sidepanels. At least one of the side panels comprises an elastomericmaterial extending laterally outwardly from the chassis, wherein theelastomeric material is joined to the second portion of the liquidimpervious film.

These and other features, aspects, and advantages of the presentinvention will become evident to those skilled in the art from a readingof the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the inventionwill be better a understood from the following description of preferredembodiments which is taken in conjunction with the accompanying drawingsand which like designations are used to designate substantiallyidentical elements, and in which:

FIG. 1 is a perspective view of a preferred embodiment of the disposablepull-on garment of the present invention in a typical in useconfiguration;

FIG. 2 is a simplified plan view of the embodiment shown in FIG. 1 inits flat uncontracted condition showing the various panels or zones ofthe garment;

FIG. 3 is a cross-sectional view of a preferred embodiment taken alongthe section line 3—3 of FIG. 2;

FIG. 4 is a cross-sectional view of an elastic member 70 of a preferredembodiment;

FIG. 5 is a fragmentary enlarged side view of the elastic member 70shown in FIG.4; and

FIG. 6 is a graph showing the two-cycles of hysteresis curves of anelastomeric material, in a preferred embodiment.

DETAILED DESCRIPTION

All cited references are incorporated herein by reference in theirentireties.

Citation of any reference is not an admission regarding anydetermination as to its availability as prior art to the claimedinvention.

As used herein, the term “pull-on garment” refers to articles of wearwhich have a defined waist opening and a pair of leg openings and whichare pulled onto the body of the wearer by inserting the legs into theleg openings and pulling the article up over the waist. The term“disposable” is used herein to describe garments which are not intendedto be laundered or otherwise restored or reused as a garment (i.e., theyare intended to be discarded after a single use and, preferably, to berecycled, composted or otherwise disposed of in an environmentallycompatible manner). A “unitary” pull-on garment refers to pull-ongarments which are formed of separate parts united together to form acoordinated entity, but the side panels are not separate elements joinedto a separate chassis in that the side panels are formed by at least onelayer which also forms the central panel or chassis of the garment(i.e., the garment does not require separately manipulative panels suchas a separate chassis and separate side panels). The pull-on garment isalso preferably “absorbent” to absorb and contain the various exudatesdischarged from the body. A preferred embodiment of the pull-on garmentof the present invention is the unitary disposable absorbent pull-ongarment, pull-on diaper 20, shown in FIG. 1. As used herein, the term“pull-on diaper” refers to pull-on garments generally worn by infantsand other incontinent individuals to absorb and contain urine and feces.It should be understood, however, that the present invention is alsoapplicable to other pull-on garments such as training pants, incontinentbriefs, feminine hygiene garments or panties, and the like. As usedherein, the term “panel” is used herein to denote an area or element ofthe pull-on garment. (While a panel is typically a distinct area orelement, a panel may coincide (functionally correspond) somewhat with anadjacent panel.) As used herein, the term “joined” or “joining”encompasses configurations whereby an element is directly secured to theother element by affixing the element directly to the other element, andconfigurations whereby the element is indirectly secured to the otherelement by affixing the element to intermediate member(s) which in turnare affixed to the other element.

Referring to FIG. 1, a disposable garment 20 of the present inventioncomprises a chassis 41 having a front region 26; a back region 28 and acrotch region 30 between the front region 26 and the back region 28; andat least one pair of side panels 46 or 48 extending laterally outwardlyfrom the chassis 41 in the front region 26 or the back region 28. The atleast one of the side panels 46 or 48 comprises an elastomeric material124 (not shown in FIG. 1) extending laterally outwardly from the chassis41. The chassis 41 comprises a liquid pervious topsheet 24, a liquidimpervious backsheet 22 associated with the topsheet 24, and anabsorbent core 25 (not shown in FIG. 1) disposed between the topsheet 24and the backsheet 22.

The backsheet 22 of the invention comprises a liquid impervious film 68.The liquid impervious film 68 of the invention extends in the front,back and crotch regions 26, 28 and 30, and has a nonuniform lateralwidth LW so as to form a first portion 94 in at least a portion of thecrotch region 30, and a second portion 96 in at least a portion of thefront or back region 26 and 28. The second portion 96 has a lateralwidth dimension less than the lateral width dimension of the firstportion 94 such that the liquid impervious film 68 does not extend intothe at least one pair of side panels (i.e., the front side panels 46 orthe back side panels 48). The elastomeric material 124 is joined to thesecond portion 96 of the liquid impervious film 68. Since the liquidimpervious film 68 does not extend into the side panels 46 or 48, theextension properties of the elastomeric material 124 are not affected bythe liquid impervious film 68 whereby the side panels 46 or 48 providean improved fitness to the body of the wearer during use.

In a preferred embodiment, the lateral width LW of the liquid imperviousfilm 68 gradually decreases towards the waist edge 152, as shown, forexample, in FIG. 2 so that the effective lateral length of theelastomeric material 124 can be increased towards the waist edge 152.

The at least one pair of side panels may be either a pair of front sidepanels 46 or a pair of back side panels 48. In a preferred embodimentwherein the disposable garment 20 is a tape type disposable diaper, theat least one pair of side panels is a pair of the back side panels 48.In an alternative preferred embodiment wherein the disposable garment 20is a pull-on type disposable diaper, the at least one pair of sidepanels comprises a pair of front side panels 46 provided in the frontregion 26 and a pair of back side panels 48 provided in the back region28, and the disposable garment 20 further comprises seams 32 eachjoining the corresponding edges of the side panels 46 and 48, therebyforming two leg openings 34 and a waist opening 36.

FIG. 1 shows one preferred embodiment of a disposable garment of thepresent invention (i.e., a pull-on diaper 20). The pull-on diaper 20comprises the chassis 41 having the front region 26, the back region 28and the crotch region 30 between the front region 26 and the back region28. The chassis 41 comprises the liquid pervious topsheet 24, the liquidimpervious backsheet 22 associated with the topsheet 24, and anabsorbent core 25 (not shown in FIG. 1 but in FIG. 2) disposed betweenthe topsheet 24 and the backsheet 22. The pull-on diaper 20 furthercomprises the front side panels 46 each extending laterally outwardlyfrom the corresponding side of the chassis 41 in the front region 26,and back side panels 48 each extending laterally outwardly from thecorresponding side of the chassis 41 in the back region 28. Preferably,at least one pair of the front and back side panels 46 and 48 areelastically extensible in at least the lateral direction. The pull-ondiaper 20 further comprises seam panels 66 each extending laterallyoutwardly from each of the front and back side panels 46 and 48; andtear open tabs 31 each extending laterally outwardly from the seampanels 66. Other preferred examples of the pull-on diaper 20 aredisclosed in U.S. Pat No. 5,569,234 to Buell et al. on Oct. 29, 1996.

Preferably at least one of, more preferably both of, the pairs of thefront and back side panels 46 and 48 is elastically extensible. As usedherein, the term “extensible” refers to materials that are capable ofextending in at least one direction to a certain degree without unduerupture. The terms “elasticity” and “elastically extensible” refer toextensible materials that have the ability to return to approximatelytheir original dimensions after the force that extended the material isremoved. As used herein, any material or element described as“extensible” may also be elastically extensible unless otherwiseprovided. The extensible side panels 46 and/or 48 provide a morecomfortable and contouring fit by initially conformably fitting thediaper to the wearer and sustaining this fit throughout the time of wearwell past when the diaper has been loaded with exudates since the sidepanels 46 and/or 48 allow the sides of the diaper to expand andcontract.

In a preferred embodiment, the front and back side panels 46 and 48 areelastically extensible only in the lateral direction. In an alternativeembodiment, the front and back side panels 46 and 48 are elasticallyextensible both in the lateral and longitudinal directions.

A continuous belt 38 is formed by the front and back side panels 46 and48, and a part of the chassis 41 about the waist opening 36. Preferably,elasticized waist bands 50 are provided in both the front region 26 andthe back region 28. The pull-on diaper 20 additionally comprises elasticleg features 52.

The continuous belt 38 acts to dynamically create fitment forces in thepull-on diaper 20 when positioned on the wearer, to maintain the pull-ondiaper 20 on the wearer even when loaded with body exudates thus keepingthe absorbent core 25 in close proximity to the wearer, and todistribute the forces dynamically generated during wear about the waistthereby providing supplemental support for the absorbent core 25 withoutbinding or bunching the absorbent core 25.

The front and back side panels 46 and 48 may be formed by unitaryelements of the pull-on diaper 20 (i.e., they are not separatelymanipulative elements secured to the pull-on diaper 20, but rather areformed from and are extensions of one or more of the various layers ofthe pull-on diaper). In a preferred embodiment, each of the front andback side panels 46 and 48 is a projected member of the chassis 41 (moreclearly shown in FIG. 2). Preferably, the front side panels 46 and backside panels 48 comprises at least one unitary element or a continuoussheet material (e.g. the backsheet nonwoven 23 in FIG. 3) that forms apart of the chassis 41 and continuously extends to the front side panels46 and back side panels 48.

In preferred embodiments, each of the seam panels 66 is an extension ofthe corresponding front and back side panels 46 and 48, or at least oneof the component elements used therein, or any other combination of theelements. Preferably, each of the tear open tabs 31 is also an extensionof the corresponding seam panels 66 or at least one of their componentelements used therein, or any other combination of the elements.

Alternatively, the front and side panels 46 and 48 may be discretemembers (not shown in FIGS.) which do not have any unitary element thatforms a part of the chassis 41. The front and side panels are formed byjoining the discrete members to the side edges of the chassis 41.

The pull-on diaper 20 further comprises seams 32 each joining thecorresponding edges of the front and side panels 46 and 48, therebyforming two leg openings 34 and a waist opening 36. Preferably, thefront and side panels 46 and 48 are seamed, more preferably through theseam panels 66, in an overlap manner to make an overlapped seamstructure. Alternatively, the front and side panels 46 and 48 can beseamed in a butt seam manner (not shown in FIGS.). The bonding of theseams 32 can be performed by any suitable means known in the artappropriate for the specific materials employed in the front and backside panels 46 and 48. Thus, sonic sealing, heat sealing, pressurebonding, adhesive or cohesive bonding, sewing, autogeneous bonding, andthe like may be appropriate techniques. Preferably, the seam panels 66are joined by a predetermined pattern of heat/pressure or ultrasonicwelds which withstands the forces and stresses generated on the diaper20 during wear.

FIG. 2 is a partially cut-away plan view of the pull-on diaper 20 ofFIG. 1 in its flat-out, uncontracted state (i.e., with elastic inducedcontraction pulled out except in the side panels 46 and 48 which areleft in their relaxed condition) with the topsheet 24 facing the viewer,prior to the side panels 46 and 48 are joined together by the seams 32.The pull-on diaper 20 has the front region 26, the back region 28opposed to the front region 26, the crotch region 30 positioned betweenthe front region 26 and the back region 28, and a periphery which isdefined by the outer perimeter or edges of the pull-on diaper 20 inwhich the side edges are designated 150 and the end edges or waist edgesare designated 152. The topsheet 24 has the body-facing surface of thepull-on diaper 20 which is positioned adjacent to the wearer's bodyduring use. The backsheet 22 has the outer-facing surface or the of thepull-on diaper 20 which is positioned away from the wearer's body. Thepull-on diaper 20 comprises the chassis 41 comprising the liquidpervious topsheet 24; the liquid impervious backsheet 22 associated withthe topsheet 24; and the absorbent core 25 positioned between thetopsheet 24 and the backsheet 22. The diaper 20 further comprises thefront and back side panels 46 and 48 extending laterally outwardly fromthe chassis 41; the elasticized leg cuffs 52; and the elasticizedwaistbands 50. The topsheet 24 and the backsheet 22 have length andwidth dimensions generally larger than those of the absorbent core 25.The topsheet 24 and the backsheet 22 extend beyond the edges of theabsorbent core 25 to thereby form the periphery of the diaper 20. Theliquid impervious backsheet 22 preferably comprises a liquid imperviousplastic film 68 which is joined to the backsheet nonwoven 23.

While the topsheet 24, the backsheet 22, and the absorbent core 25 maybe assembled in a variety of well known configurations, exemplarychassis configurations are described generally in U.S. Pat. No.3,860,003 entitled “Contractible Side Portions for Disposable Diaper”which issued to Kenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No.5,151,092 entitled “Absorbent Article With Dynamic Elastic Waist FeatureHaving A Predisposed Resilient Flexural Hinge” which issued to KennethB. Buell et al., on Sep. 29, 1992.

The pull-on diaper 20 also has two centerlines, a longitudinalcenterline 100 and a transverse centerline 110. The term “longitudinal”,as used herein, refers to a line, axis, or direction in the plane of thepull-on diaper 20 that is generally aligned with (e.g. approximatelyparallel with) a vertical plane which bisects a standing wearer intoleft and right halves when the pull-on diaper 20 is worn. The terms“transverse” and “lateral”, as used herein, are interchangeable andrefer to a line, axis or direction which lies within the plane of thediaper that is generally perpendicular to the longitudinal direction(which divides the wearer into front and back body halves). The pull-ondiaper 20 and component materials thereof also have a body-facingsurface which faces the skin of wearer in use and an outer-facingsurface which is the opposite surface to the body-facing surface.

FIG. 3 is a cross-sectional view of a preferred embodiment taken alongthe section line 3—3 of FIG. 2. The pull-on diaper 20 comprises thechassis 41 comprising the liquid pervious topsheet 24; theliquid-impervious backsheet 22 associated with the topsheet 24; and theabsorbent core 25 positioned between the topsheet 24 and the backsheet22. The diaper further comprises the front side panels 46 each extendinglaterally outwardly from the chassis 41; and the elasticized leg cuffs52. although FIG. 3 depicts only the structure of the front side panel46, preferably the back side panels 48 have the similar structures.Preferably, the chassis 41 further comprises an acquisition/distributionlayer 82 and/or an acquisition/distribution core 84 between the topsheet24 and the absorbent core 25. Each of the front side panels 46 is formedby the lamination of an extended part 72 of the barrier flap 56, anelastic member 70 and the backsheet nonwoven 74.

The absorbent core 25 may be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. The absorbent core 25 may be manufactured in awide variety of sizes and shapes (e.g., rectangular, hourglass,“T”-shaped, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; meltblown polymers including coform;chemically stiffened, modified or cross-linked cellulosic fibers; tissueincluding tissue wraps and tissue laminates; absorbent foams; absorbentsponges; superabsorbent polymers; absorbent gelling materials; or anyequivalent material or combinations of materials.

The configuration and construction of the absorbent core 25 may vary(e.g., the absorbent core 25 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or maycomprise one or more layers or structures). Further, the size andabsorbent capacity of the absorbent core 25 may also be varied toaccommodate wearers ranging from infants through adults. However, thetotal absorbent capacity of the absorbent core 25 should be compatiblewith the design loading and the intended use of the diaper 20.

A preferred embodiment of the diaper 20 has an asymmetric, modifiedhourglass-shaped absorbent core 25 having ears in the front and backwaist regions 26 and 28. Other exemplary absorbent structures for use asthe absorbent core 25 that have achieved wide acceptance and commercialsuccess are described in U.S. Pat. No. 4,610,678 entitled “High-DensityAbsorbent Structures” issued to Weisman et al. on Sep. 9, 1986; U.S. PatNo. 4,673,402 entitled “Absorbent Articles With Dual-Layered Cores”issued to Weisman et al. on Jun. 16, 1987; U.S. Pat No. 4,888,231entitled “Absorbent Core Having A Dusting Layer” issued to Angstadt onDec. 19, 1989; and U.S. Pat No. 4,834,735, entitled “High DensityAbsorbent Members Having Lower Density and Lower Basis WeightAcquisition Zones”, issued to Alemany et al. on May 30, 1989.

The chassis 41 may further comprise an acquisition/distribution core 84of chemically stiffened fibers positioned over the absorbent core 25,thereby forming a dual core system. Preferred dual core systems aredisclosed in U.S. Pat No. 5,234,423, entitled “Absorbent Article WithElastic Waist Feature and Enhanced Absorbency” issued to Alemany et al.,on Aug. 10, 1993; and in U.S. Pat No. 5,147,345, entitled “HighEfficiency Absorbent Articles For Incontinence Management” issued toYoung, LaVon and Taylor on Sep. 15, 1992. In a preferred embodiment, theacquisition/distribution core 84 comprise chemically treated stiffenedcellulosic fiber material, available from Weyerhaeuser Co. (U.S.A.)under the trade designation of CMC.

More preferably, the chassis 22 further comprises anacquisition/distribution layer 82 between the topsheet 24 and theacquisition/distribution core 84 as shown in FIG. 3. Theacquisition/distribution layer 82 is provided to help reduce thetendency for surface wetness of the topsheet 24. Theacquisition/distribution layer 82 preferably comprises carded, resinbonded hiloft nonwoven materials such as, for example, available as CodeNo. FT-6860 from Polymer Group, Inc., North America (Landisiville, N.J.,U.S.A.), which is made of polyethylene telephthalate fibers of 6 dtex,and has a basis weight of about 43 g/m².

The topsheet 24 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. Further, the topsheet 24 is liquidpervious permitting liquids (e.g., urine) to readily penetrate throughits thickness. A suitable topsheet 24 may be manufactured from a widerange of materials such as woven and nonwoven materials; polymericmaterials such as apertured formed thermoplastic films, aperturedplastic films, and hydroformed thermoplastic films; porous foams;reticulated foams; reticulated thermoplastic films; and thermoplasticscrims. Suitable woven and nonwoven materials can be comprised ofnatural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g.,polymeric fibers such as polyester, polypropylene, or polyethylenefibers) or from a combination of natural and synthetic fibers. Thetopsheet 24 is preferably made of a hydrophobic material to isolate thewearer's skin from liquids which have passed through the topsheet 24 andare contained in the absorbent core 25 (i.e., to prevent rewet). If thetopsheet 24 is made of a hydrophobic material, at least the uppersurface of the topsheet 24 is treated to be hydrophilic so that liquidswill transfer through the topsheet more rapidly. This diminishes thelikelihood that body exudates will flow off the topsheet 10 24 ratherthan being drawn through the topsheet 24 and being absorbed by theabsorbent core 25. The topsheet 24 can be rendered hydrophilic bytreating it with a surfactant. Suitable methods for treating thetopsheet 24 with a surfactant include the topsheet 24 material with thesurfactant and immersing the material into the surfactant. A moredetailed discussion of such a treatment and hydrophilicity is containedin U.S. Pat. Nos. 4,988,344 entitled “Absorbent Articles with MultipleLayer Absorbent Layers” issued to Reising, et al on Jan. 29, 1991 andU.S. Pat. No. 4,988,345 entitled “Absorbent Articles with RapidAcquiring Absorbent Cores” issued to Reising on Jan. 29, 1991.

In preferred embodiments, the topsheet 24 is a nonwoven web that canprovide reduced tendency for surface wetness; and consequentlyfacilitate maintaining urine absorbed by the core 25 away from theuser's skin, after wetting. One of the preferred topsheet materials is athermobonded carded web which is available as Code No. P-8 from FiberwebNorth America, Inc. (Simpsonville, S.C., U.S.A.). Another preferredtopsheet material is available as Code No. S-2355 from Havix Co., Japan.This material is a bi-layer composite material, and made of two kinds ofsynthetic surfactant treated bicomponent fibers by using carding andair-through technologies. Yet another preferred topsheet material is athermobonded carded web which is available as Code No. Profleece Style040018007 from Amoco Fabrics, Inc. (Gronau, Germany).

Another preferred topsheet 24 comprises an apertured formed film.Apertured formed films are preferred for the topsheet 24 because theyare pervious to body exudates and yet non-absorbent and have a reducedtendency to allow liquids to pass back through and rewet the wearer'sskin. Thus, the surface of the formed film which is in contact with thebody remains dry, thereby reducing body soiling and creating a morecomfortable feel for the wearer. Suitable formed films are described inU.S. Pat No. 3,929,135, entitled “Absorptive Structures Having TaperedCapillaries”, which issued to Thompson on Dec. 30, 1975; U.S. Pat. No.4,324,246 entitled “Disposable Absorbent Article Having A StainResistant Topsheet”, which issued to Mullane, et al. on Apr. 13, 1982;U.S. Pat. No. 4,342,314 entitled “Resilient Plastic Web ExhibitingFiber-Like Properties”, which issued to Radel. et al. on Aug. 3, 1982;U.S. Pat No. 4,463,045 entitled “Macroscopically ExpandedThree-Dimensional Plastic Web Exhibiting Non-Glossy Visible Surface andCloth-Like Tactile Impression”, which issued to Ahr et al. on Jul. 31,1984; and U.S. Pat. No. 5,006,394 “Multilayer Polymeric Film” issued toBaird on Apr. 9, 1991.

In preferred embodiments, the backsheet 22 comprises the liquidimpervious film 68 as shown in, for example, FIG. 3. The liquidimpervious film 68 has a body-facing surface 79 and an outer-facingsurface 77. The liquid impervious film 68 is preferably impervious toliquids (e.g., urine) and is preferably manufactured from a thin plasticfilm. However, more preferably the plastic film permits vapors to escapefrom the diaper 20. In a preferred embodiment, a microporouspolyethylene film is used for the plastic film 68. A suitablemicroporous polyethylene film is manufactured by Mitsui ToatsuChemicals, Inc., Nagoya, Japan and marketed in the trade as Espoir No.

A suitable material for the plastic film 68 is a thermoplastic filmhaving a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm(2.0 mils), preferably comprising polyethylene or polypropylene.Preferably, the plastic film has a basis weight of from about 5 g/m² toabout 35 g/m². However, it should be noted that other flexible liquidimpervious materials may be used. As used herein, the term “flexible”refers to materials which are compliant and which will readily conformto the general shape and contours of the wearers body.

Preferably, the backsheet 22 further comprises a nonwoven outer cover 23which is joined with the outer-facing surface of the plastic film 68 toform a laminate (i.e., the backsheet 22). The nonwoven outer cover 23 ispositioned at the outermost portion of the diaper 20 and covers at leasta portion of the outermost portion of the diaper 20. In a preferredembodiment, the nonwoven outer cover 23 covers almost all of the area ofthe outermost portion of the diaper 20. The nonwoven outer cover 23 maybe joined to the plastic film 68 by any suitable attachment means knownin the art. For example, the nonwoven outer cover 23 may be secured tothe plastic film 68 by a uniform continuous layer of adhesive, apatterned layer of adhesive, or an array of separate lines, spirals, orspots of adhesive. Suitable adhesives include a hotmelt adhesiveobtainable from Nitta Findley Co., Ltd., Osaka, Japan as H-2128, and ahotmelt adhesive obtainable from H. B. Fuller Japan Co., Ltd., Osaka,Japan as JM-6064.

In a preferred embodiment, the nonwoven outer cover 23 is a cardednonwoven web, for example, obtainable from Havix Co., LTD., Gifu, Japanas E-2341. The nonwoven outer cover 23 is made of bi-component fibers ofa polyethylene (PE) and a polyethylene terephthalate (PET). The ratio ofPE/PET is about 40/60. The PE/PET bi-component fiber has the dimensionof 2d×51 mm. Another preferred carded nonwoven web is obtainable fromChisso Corp., Osaka, Japan. The nonwoven outer cover 23 is also made ofbi-component fibers of a polyethylene (PE) and a polyethyleneterephthalate (PET). The ratio of PE/PET is about 30/70.

In another preferred embodiment, the nonwoven web is a spunbondednonwoven web, for example, obtainable from Mitsui PetrochemicalIndustries, Ltd., Tokyo, Japan. The nonwoven web is made of bi-componentfibers of a polyethylene (PE) and a polypropylene (PP). The ratio ofPE/PP is about 80/20. The PEIPP bi-component fiber has the thickness isapproximately 2.3d.

The backsheet 22 is preferably positioned adjacent the outer-facingsurface of the absorbent core 25 and is preferably joined thereto by anysuitable attachment means known in the art. For example, the backsheet22 may be secured to the absorbent core 25 by a uniform continuous layerof adhesive, a patterned layer of adhesive, or an array of separatelines, spirals, or spots of adhesive. Adhesives which have been found tobe satisfactory are manufactured by H. B. Fuller Company of St. Paul,Minn. and marketed as HL-1258. An example of a suitable attachment meanscomprising an open pattern network of filaments of adhesive is disclosedin U.S. Pat No. 4,573,986 entitled “Disposable Waste-ContainmentGarment”, which issued to Minetola et al. on Mar. 4, 1986. Anothersuitable attachment means comprising several lines of adhesive filamentsswirled into a spiral pattern is illustrated by the apparatus andmethods shown in U.S. Pat No. 3,911,173 issued to Sprague, Jr. on Oct.7, 1975; U.S. Pat No. 4,785,996 issued to Ziecker, et al. on Nov. 22,1978; and U.S. Pat No. 4,842,666 issued to Werenicz on Jun. 27, 1989.Alternatively, the attachment means may comprise heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment means or combinations of these attachment means as are knownin the art.

In an alternative embodiment, the absorbent core 25 is not joined to thebacksheet 22, and/or the topsheet 24 in order to provide greaterextensibility in the front region 26 and the back region 28.

The pull-on diaper 20 preferably further comprises elasticized leg cuffs52 for providing improved containment of liquids and other bodyexudates. The elasticized leg cuffs 52 may comprise several differentembodiments for reducing the leakage of body exudates in the legregions. (The leg cuff can be and is sometimes also referred to as legbands, side flaps, barrier cuffs, or elastic cuffs.) U.S. Pat. No.3,860,003 describes a disposable diaper which provides a contractibleleg opening having a side flap and one or more elastic members toprovide an elasticized leg cuff (gasketing cuff). U.S. Pat. No.4,909,803 entitled “Disposable Absorbent Article Having ElasticizedFlaps” issued to Aziz et al. on Mar. 20, 1990, describes a disposablediaper having “stand-up” elasticized flaps (barrier cuffs) to improvethe containment of the leg regions. U.S. Pat. No. 4,695,278 entitled“Absorbent Article Having Dual Cuffs” issued to Lawson on Sep. 22, 1987;and U.S. Pat. No. 4,795,454 entitled “Absorbent Article HavingLeakage-Resistant Dual Cuffs” issued to Dragoo on Jan. 3, 1989, describedisposable diapers having dual cuffs including a gasketing cuff and abarrier cuff. U.S. Pat. No. 4,704,115 entitled “Disposable WaistContainment Garment” issued to Buell on Nov. 3, 1987, discloses adisposable diaper or incontinence garment having side-edge-leakageguardgutters configured to contain free liquids within the garment.

While each elasticized leg cuff 52 may be configured so as to be similarto any of the leg bands, side flaps, barrier cuffs, or elastic cuffsdescribed above, it is preferred that each elasticized leg cuff 52comprises inner barrier cuffs 54 each comprising a barrier flap 56 and aspacing means 58 (as shown in FIGS. 1 and 2) as described in theabove-referenced U.S. Pat No. 4,909,803. In a preferred embodiment, theelasticized leg cuff 52 additionally comprises an elastic gasketing cuff62 with one or more elastic strands 64 (as shown in FIG. 2), positionedoutboard of the barrier cuff 54 such as described in the above-referredU.S. Pat. Nos. 4,695,278 and 4,795,454.

The pull-on diaper 20 preferably further comprises an elasticizedwaistband 50 that provides improved fit and containment. The elasticizedwaistband 50 is that portion or zone of the pull-on diaper 20 which isintended to elastically expand and contract to dynamically fit thewearer's waist. The elasticized waistband 50 preferably extendslongitudinally outwardly from at least one of the waist edges of theabsorbent core 25 and generally forms at least a portion of the end edgeof the pull-on diaper 20. Preferably, the pull-on diaper 20 has twoelasticized waistbands 50, one positioned in the back region 28 and onepositioned in the front region 26, although other pull-on diapers can beconstructed with a single elasticized waistband. The elasticizedwaistband 50 may be constructed in a number of different configurationsincluding those described in U.S. Pat. No. 4,515,595 entitled“Disposable Diapers with Elastically Contractible Waistbands” issued toKievit et al. on May 7, 1985 and the above referenced U.S. Pat. No.5,151,092 issued to Buell.

The waistbands 50 may comprise materials that have been “prestrained”,or “mechanically prestrained” (i.e., subjected to some degree oflocalized pattern mechanical stretching to permanently elongate thematerial. The materials may be prestrained using deep embossingtechniques as are known in the art. Alternatively, the materials may beprestrained by directing the material through an incremental mechanicalstretching system as described in U.S. Pat No. 5,330,458 entitled“Absorbent Article With Elastic Feature Having A Portion MechanicallyPrestrained” issued to Buell et al., on Jul. 19, 1994. The materials arethen allowed to return to their substantially untensioned condition,thus forming a zero strain stretch material that is extensible, at leastup to the point of initial stretching. Examples of zero strain materialsare disclosed in U.S. Pat No. 2,075,189 issued to Galligan on Mar. 30,1937; U.S. Pat No. 3,025,199 issued to Harwood on Mar. 13, 1962; U.S.Pat. Nos. 4,107,364 and 4,209,563 issued to Sisson on Aug. 15, 1978 andJun. 24, 1980, respectively; U.S. Pat No. 4,834,741 issued to Sabee onMay 30, 1989; and U.S. Pat No. 5,151,092 issued to Buell et al., on Sep.29, 1992.

Referring to FIG. 3, at least one of the front and back side panels(i.e., the front side panels 46 in this embodiment) comprises theelastic member 70. The elastic member 70 comprises the elastomericmaterial 124 which preferably extends laterally outwardly from thechassis 41 to provide a good fitness by generating the optimal retention(or sustained) force at the waist area of the wearer. Preferably, theelastomeric material 124 is extensible in at least one direction,preferably in a direction having a vector component in the lateraldirection to generate a retention (or sustained) force that is optimalto prevent the pull-on diaper 20 from drooping, sagging, or sliding downfrom its position on the torso without causing the red marking on theskin of the wearer. In preferred embodiments, both of the front and backside panels 46 and 48 comprise the elastomeric material 124.

The elastic member 70 comprising the elastomeric material 124 (not shownin FIG. 3) is operatively joined to at least one of the nonwoven webs 72and 74 in the front and back side panels 46 and 48 to allow the elasticmember 70 to be elastically extensible in at least the lateraldirection. In a preferred embodiment, the elastic member 70 isoperatively joined to the nonwoven webs 72 and 74 by securing them to atleast one, preferably both of the nonwoven webs 72 and 74 while in asubstantially untensioned (zero strain) condition.

The elastic member 70 can be operatively joined to the nonwoven webs 72and 74, by using either an intermittent bonding configuration or asubstantially continuous bonding configuration. As used herein, an“intermittently” bonded laminate web means a laminate web wherein theplies are initially bonded to one another at discrete spaced apartpoints or a laminate web wherein the plies are substantially unbonded toone another at discrete spaced apart areas. Conversely, a “substantiallycontinuously” bonded laminate web means a laminate web wherein the pliesare initially bonded substantially continuously to one anotherthroughout the areas of interface. Because it is preferred that thestretch laminate be bonded over all or a significant portion of thestretch laminate so that the inelastic webs (i.e., the nonwoven webs 72and 74) elongate or draw without causing rupture, and the layers of thestretch laminates are preferably bonded in a configuration thatmaintains all of the layers of the stretch laminate in relatively closeadherence to one another after the incremental mechanical stretchingoperation, the elastic panel members and the other plies of the stretchlaminate are substantially continuously bonded together using anadhesive. In a particularly preferred embodiment, the adhesive selectedis applied in a spiral pattern (such as is shown in U.S. Pat. No.3,911,173 (Sprague, Jr.) and U.S. Pat. No. 4,842,666 (Werenicz)) at abasis weight of about 0.00116 grams/square cm (0.0075 grams/squareinch). The spirals have a width of about 1.9 cm (0.75 in) and either arepositioned just next to each other or overlap slightly (less than 2 mm).The adhesive is preferably an adhesive such as is available from FindleyAdhesives under the designation H2120. Alternatively, the elastic panelmember and any other components of the stretch laminates may beintermittently or continuously bonded to one another using heat bonding,pressure bonding, ultrasonic bonding, dynamic mechanical bonding, or anyother method as is known in the art.

After the elastic member 70 is operatively joined to at least one of thenonwoven webs 72 and 74, at least a portion of the resultant compositestretch laminate is then subjected to mechanical stretching sufficientto permanently elongate the non-elastic components which are, forexample, the nonwoven webs 72 and 74. The composite stretch laminate isthen allowed to return to its substantially untensioned condition. Atleast one pair of, preferably both of the front and back side panels 46and 48 is thus formed into “zero strain” stretch laminates.(Alternatively, the elastic member 70 could be operatively joined in atensioned condition and then subjected to mechanical stretching;although this is not as preferred as a “zero strain” stretch laminate.)As used herein, the term “zero strain” stretch laminate refers to alaminate comprised of at least two plies of material which are securedto one another along at least a portion of their coextensive surfaceswhile in a substantially untensioned (“zero strain”) condition; one ofthe plies comprising a material which is stretchable and elastomeric(i.e., will return substantially to its untensioned dimensions after anapplied tensile force has been released) and a second ply which iselongatable (but not necessarily elastomeric) so that upon stretchingthe second ply will be, at least to a degree, permanently elongated sothat upon release of the applied tensile forces, it will not fullyreturn to its original undeformed configuration. The resulting stretchlaminate is thereby rendered elastically extensible, at least up to thepoint of initial stretching, in the direction of initial stretching.Particularly preferred methods and apparatus used for making stretchlaminates utilize meshing corrugated rolls to mechanically stretch thecomponents. Particularly preferred apparatus and methods are disclosedin U.S. Pat. No. 5,167,897 issued to Weber et al. on Dec. 1, 1992; U.S.Pat No. 5,156,793 issued to Buell et al. on Oct. 20, 1990; and U.S. PatNo. 5,143,679 issued to Weber et al. on Sep. 1, 1992. It should be notedthat the Japanese equivalent applications to these U.S. Patents werepublished (laid open) in Japanese under the Nos. of H6-505681, H6-505408and H6-505446, respectively.

The elastic member 70 is preferably joined to, more preferably directlysecured to the respective edges 78 of the liquid impervious film (i.e.,the plastic film 68) though an adhesive 76 as shown in FIG. 3. In apreferred embodiment, the elastic member 70 is joined to the respectiveedges 78 of the plastic film 68 at the outer-facing surface 77 as shownin FIG. 3. In an alternative embodiment, the elastic member 70 may bejoined to the respective edges 78 of the plastic film 68 at thebody-facing surface 79 (not shown in FIGS.). Preferably, the adhesive 76is applied as an bead. In preferred embodiments, the adhesive 76 is aflexible adhesive with an amorphous and crystallizing component. Such apreferred adhesive is made by the Findley Adhesive Company under thedesignation H9224. Alternatively, the elastic member 70 may be joined tothe respective edges 78 of the plastic film 68 by any other bondingmeans known in the art which comprise heat bonds, pressure bonds,ultrasonic bonds, dynamic mechanical bonds, or combinations of theseattachment means.

Referring to FIG. 4, the elastic member 70 comprises the elastomericmaterial 124 having a first surface 150 and a second surface 152opposing the first surface 150, and a first coverstock layer 122 whichis joined to the first surface 150 of the elastomeric material 124. In apreferred embodiment, the first coverstock layer 122 is joined to thefirst surface 150 of the elastomeric material 124 by an adhesive 160 asshown, for example, in FIG. 5. More preferably, the elastic member 70further comprises a second coverstock layer 126 which is joined to thesecond surface 152 of the elastomeric material 124 by an adhesive 164.

Preferably, the elastic member 70 is joined to the respective edges 78of the plastic film 68 at the outer-facing surface 77 as shown in FIG.3. In an alternative embodiment, the elastic member 70 may be joined tothe respective edges 78 of the plastic film 68 at the body-facingsurface 79 (not shown in FIGS.).

The elastomeric material 124 may be formed in a wide variety of sizes,forms and shapes. In a preferred embodiment, the elastomeric material124 is in the form of a continuous plane layer. Preferred forms ofcontinuous plane layer include a scrim, a perforated (or aperturesformed) film, an elastomeric woven or nonwoven, and the like. In analternative embodiment, the elastomeric material 124 is in the form ofstrands (or strings) which are not connected each other to form acontinuous plane layer. The continuous plane layer may take any shapewhich can be suitably provided in the side panels. Preferred shapes ofcontinuous plane layer include a quadrilateral including a rectangle anda square, a trapezoid, and the other polygons.

Elastomeric materials which have been found to be especially suitablefor the elastomeric material 124 are styrenic block copolymer basedscrim materials, perforated (or apertured) elastic films, preferablywith a thickness of from about 0.05 mm to about 1.0 mm (0.002 inch-0.039inch). Other suitable elastomeric materials for the elastomeric material124 include “live” synthetic or natural rubber, other synthetic ornatural rubber foams, elastomeric films (including heat shrinkableelastomeric films), elastomeric woven or nonwoven webs, elastomericcomposites, or the like.

The extension properties of the elastomeric material 124 such as theFirst Cycle Extension Force at 100% Extension (FCEF100%), the FirstCycle Extension Force at 200% Extension (FCEF200%), and the Second CycleRecovery Force at 50% Extension (SCRF50%) are important considerationsin the performance of disposable garments. The elastomeric material 124preferably has extension properties within the defined ranges herein.The FCEF100% and the FCEF200% are measures of the overall perceived“stretchness” during application/removing of disposable garments. Thesetwo properties also effect the ability of the applicator to achieve asuitable degree of application stretch. An elastomeric material 124 witha relatively high FCEF100% and FCEF200% can causes difficulty inapplying the disposable garment onto the wearer (i.e., ease ofapplication problem). On the other hand, an elastomeric material 124with a relatively low FCEF100% and FCEF200% may not achieve a suitablelevel of body fitting/conformity. The SCRF50% also closely relates tothe body fitting/conformity of disposable garments for the wearer. Anelastomeric material 124 with a relatively high SCRF50% tends to causered marking on the skin of the wearer and may be uncomfortable for thewearer during usage. An elastomeric material 124 with a relatively lowSCRF50% may not provide enough elastic force to keep the diaper in placeon the wearer or may not provide good body fit.

The values of FCEF100%, FCEF200% and SCRF50% can be measured by using atensile tester. The tensile tester comprises an upper jaw and a lowerjaw which is located below the upper jaw. The upper jaw is movable andis connected to an extension force measuring means. The lower jaw isfixed at a desk (or floor). A test specimen (i.e., the elastomericmaterial to be measured) which has about 2.54 cm (1.0 inch) in width andabout 12.75 cm (5 inches) in length is prepared and clamped between theupper jaw and the lower jaw so that the effective specimen length (L)(i.e., gauge length) is about 5.08 cm (2.0 inches). The extension forceis applied to the test specimen through the upper jaw. When no extensionforce is applied to the test specimen, the test specimen is in itsoriginal length (i.e., 0% extension). A tensile tester suitable for useherein is available from Instron Corporation (100 Royall Street, Canton,MA02021, U.S.A.) as Code No. Instron 5564.

FIG. 6 shows one preferred example of the extension and recovery forcecurves for the two cycle hysteresis of the elastomeric material 124. Thecurve E1 shows the extension force in the first cycle, while the curveR1 shows the recovery force in the first cycle. The curve E2 (shown indashed lines) shows the extension force in the second cycle, while thecurve R2 shows the recovery force in the second cycle. The extension andrecovery properties are measured as follows.

In the first cycle, the test specimen is subjected to an initialextension force at a crosshead rate of 50.8 cm/min (20 in/min) at about23° C. and held for 30 seconds at 200% extension. The test specimen isthen allowed to relax at the same rate to the original state (i.e., 0%extension). The test specimen is allowed to remain unconstrained for oneminute before being subjected to a second extension force (for thesecond cycle) at the same rate and conditions.

In preferred embodiments, the FCEF100% of the elastomeric material 124is at least about 100 grams/inch. More preferably, the FCEF100% isbetween about 120 to about 220 grams/inch, most preferably between about150 grams/inch and 190 grams/inch to best fit the wearer. The FCEF200%is preferably between about 160 grams/inch and about 320 grams/inch,more preferably between about 180 grams/inch and about 260 grams/inch,and yet more preferably between about 200 grams/inch and about 240grams/inch.

The SCRF50% of the elastomeric material 124 is preferably between about40 grams/inch and about 130 grams/inch, more preferably between about 65grams/inch and about 105 grams/inch, and yet more preferably betweenabout 75 grams/inch and about 95 grams/inch.

In the preferred embodiment shown in FIG. 4, the elastomeric scrim 124has a plurality of first strands 125 and a plurality of second strands127. The plurality of first strands 125 intersect the plurality ofsecond strands 127 at nodes 130 at a predetermined angle α, forming anet-like open structure having a plurality of apertures 132. Eachaperture 132 is defined by at least two adjacent first strands and atleast two adjacent second strands, so that the apertures 132 aresubstantially rectangular in shape. Other configurations of theapertures 132, such as parallelograms, squares, or circular arcsegments, can also be provided. Preferably, the first and second strands125 and 127 are substantially straight and substantially parallel to oneanother. Preferably, the first strands 125 intersect the second strands127 at nodes 130 such that the angle α is about 90 degrees. The firstand second strands 125 and 127 are preferably joined or bonded at nodes90.

A preferred elastomeric scrim 124 is manufactured by the Conwed PlasticsCompany under the designation XO2514. This material has about 12 elasticstrands per inch in the structural direction B (i.e., the first strands125) and about 7 elastic strands per inch in the structural direction D(i.e., the second strands 127).

In the embodiment shown in FIG. 4, the elastic member 70 comprises firstand second coverstock layers 122 and 126, and elastomeric material 124disposed in the first and second coverstock layers 122 and 126. Thefirst coverstock layer 122 has an inner surface 142 and an outer surface144. The inner surface 142 of the first coverstock layer 122 is thesurface that is positioned facing the elastomeric material 124. Thesecond coverstock layer 126 also has an inner surface 146 and an outersurface 148. The inner surface 146 of the second coverstock layer 126 isthe surface that is positioned facing the elastomeric material 124. Theelastomeric material 124 also has two planar surfaces, first surface 150and second surface 152, each of which is substantially parallel with theplanes of the first and second coverstock layers 122 and 126. The firstsurface 150 is that planar surface of the elastomeric material 124 thatis most closely adjacent with the inner surface 142 of first coverstocklayer 122. The second surface 152 is that planar surface of elastomericmaterial 124 that is most closely adjacent to the inner surface 146 ofthe second coverstock layer 126.

Since the elastic member 70 will be subjected to mechanical stretchingbefore and during use, the first and second coverstock layers 122 and126 preferably has a relatively high elongation at breaking, and aremore preferably stretchable or elongatable, yet more preferably drawable(but not necessarily elastomeric), without undue and preferably withoutany, tearing or ripping. Further, the first and second coverstock layers122 and 126 are preferably compliant, soft feeling, and non-irritatingto the wearer's skin and give the article the feel and comfort of acloth garment. Suitable materials for the first and second coverstocklayers 122 and 126 can be manufactured from a wide range of materialssuch as plastic films, apertured plastic films, woven or nonwoven websof natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyolefins, polyamides, polyester, polyethylene, or polypropylenefibers), or a combination of natural and/or synthetic fibers, or coatedwoven or nonwoven webs.

Preferably, each of the first and second coverstock layers 122 and 126is an identical consolidated nonwoven material. An exemplary preferrednonwoven material is manufactured by the FiberWeb Company under thedesignation Sofspan 200. This material has a basis weight of 25 g/m²before consolidation and a basis weight of about 63 g/m2 afterconsolidation. As used herein, “basis weight” is the weight of onesquare meter of planar web material. Alternatively, highly strainablenonwoven materials may be used. Alternatively, the first and secondcoverstock layers 122 and 126 need not be of identical materials, aslong as the desired performance requirements, such as elasticperformance, softness, flexibility, breathability and durability, aremet. As used herein, “consolidated nonwoven material” means a nonwovenmaterial that has been gathered or necked under mechanical tension inthe structural direction D so that the material can elongate in thestructural direction D under low force.

FIG. 5 shows a fragmentary enlarged side view looking into thestructural direction B of the laminate 120 (i.e., the elastic member70). It has been found that when the laminate 120 is bonded or otherwiseanchored such that side anchor zones A are created, such a laminate 120is both highly elastic and substantially free from delamination andcreep, while providing very good performance characteristics in allperformance categories with no trade-offs between any performancecharacteristics required. The side anchoring is preferably performed byside gluing with adhesive beads to anchor the elastomeric material 124between the coverstock layers 122 and 126 as a part of the laminationprocess. Alternatively, side anchoring may be performed by sewing, heatsealing, ultrasound bonding, needle punching, alternative gluingprocesses, or by any other means known to those skilled in the art.Another alternative is to side anchor the layers of the laminatestructure after the lamination of the elastomeric and coverstockcomponents has been performed.

Preferably, the laminate 120 may particularly provide very good softfeel for the wearer and for the consumer. This is important becauseconsumers value softness. In conventional laminates, the attempts toeliminate creep have frequently required an unacceptable decrease insoftness, often accompanied by an unacceptable decrease in the abilityto activate. This is because such previous attempts (which have fallenshort of eliminating creep) have focused on the application ofadditional melt blown adhesive, often in an overall coating pattern inthe attempt to strengthen the bonds. This has generally resulted in anundesirable overall stiffening of the laminate. However, the laminatesof the preferred embodiments provide elimination of creep without theloss of consumer-desired soft feel and without compromise of activationability.

Referring to FIG. 5, a first adhesive 170 is applied to the innersurface 146 of the second coverstock layer 126 in positions thatcorrespond to each of the outer edges 180 of the laminate structure 120.The first adhesive 170 may alternatively or additionally be applied tothe inner surface 142 of the first coverstock layer 122. For ease ofillustration, the description and FIGS. refer to application to thesecond coverstock layer 126 only.

This pattern creates side anchor zones A, which substantially eliminatethe delamination and creep associated with previously known laminatesand which allows the laminate 120 to experience higher strains withoutcreeping or delaminating. It has also been found that confining thefirst adhesive 170 to the edge areas 180 of the laminate structure 120avoids impeding the extensibility of the laminate 120 and also avoidstears in the coverstock layers 122 and 126. Preferably, the firstadhesive 170 is applied as a plurality of beads 168, as shown in FIG. 5.Preferably, the first adhesive 170 is a flexible adhesive with anamorphous and crystallizing component. Such a preferred adhesive is madeby the Findley Adhesive Company under the designation H9224.

More preferably, the laminate 120 includes a second adhesive 164. Thesecond adhesive 164 is preferably applied to the second surface 152 ofthe elastomeric material 124, but could alternatively be applied to thefirst surface 150 of the elastomeric material 24. The second adhesive164 is preferably applied in a spiral spray pattern 166, thereby formingbond points 167 b that are more discrete than would be formed by alinear spray application. Without being bound by theory, it is believedthat most of the second adhesive 164 so sprayed aligns in the structuraldirection D. Thus, it has been found that spiral spraying results invery good activation properties. As used herein, “activation” refers tothe ability to stretch.

It has been found that spraying the layer of second adhesive 164directly onto the second surface 152 of the elastomeric material 124 ismore preferable than applying the second adhesive 164 to the opposing(i.e., second) coverstock layer 126. This is because the second adhesive164 tends to penetrate through any residual processing agents or oilsthat may remain on the surface of the elastomeric material 124. Suchresidual materials, if left to remain on the elastomeric material 124,may weaken the adhesive bonds and thus the laminate structure 120 overtime. For example, if these residual materials are left intact, thebonds used to form the laminate 120 may weaken during the time intervalprior to consumer purchase of the product.

Peel values for the laminate 120 in the spiral adhesive areas aretypically higher when the spirals 166 are applied directly to theelastomeric material 124 than to the opposing (i.e., second) coverstocklayer 126. As used herein, the term “peel value” refers to the amount offorce required to separate the two layers of coverstock material, 122and 126, from each other. Higher peel values typically equate to lesschance of delamination in use.

A third adhesive 160 may also preferably be applied to the inner surface142 of the first coverstock layer 122. Preferably, the third adhesive160 is an elastomeric adhesive. In a manner similar to that describedwith reference to the second spiral adhesive application 166, the firstadhesive 160 is preferably applied in a spiral spray pattern 162,thereby forming bond points 167 a that are more discrete than would beformed by a linear spray application. Without being bound by theory, itis believed that most of the first adhesive 160 so sprayed aligns in thestructural direction D.

Preferably, second and third adhesives 160 and 164 are the sameelastomeric adhesive. A preferred adhesive for use in the second andthird adhesive spiral sprays 162 and 166 is made by the Findley AdhesiveCompany under the designation H2120. Preferably, the add-on level foreach of the second and third spiral sprays 162 and 166 is about 4 toabout 12 milligrams per square inch, more preferably about 8 milligramsper square inch.

It is understood that the examples and embodiments described herein arefor illustrative purpose only and that various modifications or changeswill be skilled in the art without departing from the scope of thepresent invention.

What is claimed is:
 1. A disposable garment, comprising: a chassishaving a front region, a back region and a crotch region between thefront region and back region, the chassis comprising a liquid pervioustopsheet, a liquid impervious backsheet associated with the topsheet,and an absorbent core disposed between the topsheet and the backsheet;and at least one pair of side panels extending laterally outwardly fromthe chassis in the front or back region; the backsheet comprising aliquid impervious film having a body-facing surface and extendinglongitudinally in the front, back and crotch regions, the liquidimpervious film having a nonuniform lateral width so as to form a firstportion in at least a portion of the crotch region, and a second portionin at least a portion of the front or back region, the second portionhaving a lateral width dimension less than the lateral width dimensionof the first portion when the garment is in a flat uncontractedcondition such that the film does not extend into the at least one pairof side panels; at least one of the side panels comprising anelastomeric material extending laterally outwardly from the chassis;wherein the elastomeric material is joined to the second portion of theliquid impervious film at the body-facing surface.
 2. The disposablegarment according to claim 1, wherein the lateral width of the liquidimpervious film gradually decreases towards the waist edge.
 3. Adisposable garment, comprising: a chassis having a front region, a backregion and a crotch region between the front region and back region, thechassis comprising a liquid pervious topsheet, a liquid imperviousbacksheet associated with the topsheet, and an absorbent core disposedbetween the topsheet and the backsheet; and at least one pair of sidepanels extending laterally outwardly from the chassis in the front orback region; the backsheet comprising a liquid impervious film extendinglongitudinally in the front, back and crotch regions, the liquidimpervious film having a nonuniform lateral width so as to form a firstportion in at least a portion of the crotch region, and a second portionin at least a portion of the front or back region, the second portionhaving a lateral width dimension less than the lateral width dimensionof the first portion when the garment is in a flat uncontractedcondition such that the film does not extend into the at least one pairof side panels; at least one of the side panels comprising anelastomeric material extending laterally outwardly from the chassis andjoined to the second portion of the liquid impervious film; wherein theat least one pair of side panels is a pair of back side panels providedin the back region.
 4. A disposable garment, comprising: a chassishaving a front region, a back region and a crotch region between thefront region and back region, the chassis comprising a liquid pervioustopsheet, a liquid impervious backsheet associated with the topsheet,and an absorbent core disposed between the topsheet and the backsheet;and at least one pair of side panels extending laterally outwardly fromthe chassis in the front or back region; the backsheet comprising aliquid impervious film extending longitudinally in the front, back andcrotch regions, the liquid impervious film having a nonuniform lateralwidth so as to form a first portion in at least a portion of the crotchregion, and a second portion in at least a portion of the front or backregion, the second portion having a lateral width dimension less thanthe lateral width dimension of the first portion when the garment is ina flat uncontracted condition such that the film does not extend intothe at least one pair of side panels; at least one of the side panelscomprising an elastomeric material extending laterally outwardly fromthe chassis and Joined to the second portion of the liquid imperviousfilm; wherein the at least one of the side panels is formed from a “zerostrain” stretch laminate.
 5. A disposable garment, comprising: a chassishaving a front region, a back region and a crotch region between thefront region and back region, the chassis comprising a liquid pervioustopsheet, a liquid impervious backsheet associated with the topsheet,and an absorbent core disposed between the topsheet and the backsheet;and at least one pair of side panels extending laterally outwardly fromthe chassis in the front or back region; the backsheet comprising aliquid impervious film extending longitudinally in the front, back andcrotch regions, the liquid impervious film having a nonuniform lateralwidth so as to form a first portion in at least a portion of the crotchregion, and a second portion in at least a portion of the front or backregion, the second portion having a lateral width dimension less thanthe lateral width dimension of the first portion when the garment is ina flat uncontracted condition such that the film does not extend intothe at least one pair of side panels; at least one of the side panelscomprising an elastomeric material extending laterally outwardly fromthe chassis and joined to the second portion of the liquid imperviousfilm; wherein the at least one pair of side panels comprises a pair offront side panels provided in the front region and a pair of back sidepanels provided in the back region, and the disposable garment furthercomprises seams each joining the corresponding edges of the side panels,thereby forming two leg openings and a waist opening.
 6. The disposablegarment according to claim 5, wherein the corresponding front and backside panels are seamed in an overlap manner to make an overlapped seamstructure.
 7. A disposable garment, comprising: a chassis having a frontregion, a back region and a crotch region between the front region andback region, the chassis comprising a liquid pervious topsheet, a liquidimpervious backsheet associated with the topsheet, and an absorbent coredisposed between the topsheet and the backsheet; and at least one pairof side panels extending laterally outwardly from the chassis in thefront or back region; the backsheet comprising a liquid impervious filmextending longitudinally in the front, back and crotch regions, theliquid impervious film having a nonuniform lateral width so as to form afirst portion in at least a portion of the crotch region, and a secondportion in at least a portion of the front or back region, the secondportion having a lateral width dimension less than the lateral widthdimension of the first portion when the garment is in a flatuncontracted condition such that the film does not extend into the atleast one pair of side panels; at least one of the side panelscomprising an elastomeric material extending laterally outwardly fromthe chassis and joined to the second portion of the liquid imperviousfilm; wherein the backsheet further comprises a nonwoven outer coverjoined to the liquid impervious film.
 8. A disposable garment,comprising: a chassis having a front region, a back region and a crotchregion between the front region and back region, the chassis comprisinga liquid pervious topsheet, a liquid impervious backsheet associatedwith the topsheet, and an absorbent core disposed between the topsheetand the backsheet; and at least one pair of side panels extendinglaterally outwardly from the chassis in the front or back region; thebacksheet comprising a liquid impervious film extending longitudinallyin the front, back and crotch regions, the liquid impervious film havinga nonuniform lateral width so as to form a first portion in at least aportion of the crotch region, and a second portion in at least a portionof the front or back region, the second portion having a lateral widthdimension less than the lateral width dimension of the first portionwhen the garment is in a flat uncontracted condition such that the filmdoes not extend into the at least one pair of side panels; at least oneof the side panels comprising an elastomeric material extendinglaterally outwardly from the chassis and joined to the second portion ofthe liquid impervious film; wherein the elastomeric material is anelastomeric scrim.
 9. A disposable garment, comprising: a chassis havinga front region, a back region and a crotch region between the frontregion and back region, the chassis comprising a liquid pervioustopsheet, a liquid impervious backsheet associated with the topsheet,and an absorbent core disposed between the topsheet and the backsheet;and at least one pair of side panels extending laterally outwardly fromthe chassis in the front or back region; the backsheet comprising aliquid impervious film extending longitudinally in the front, back andcrotch regions, the liquid impervious film having a nonuniform lateralwidth so as to form a first portion in at least a portion of the crotchregion, and a second portion in at least a portion of the front or backregion, the second portion having a lateral width dimension less thanthe lateral width dimension of the first portion when the garment is ina flat uncontracted condition such that the film does not extend intothe at least one pair of side panels; at least one of the side panelscomprising an elastomeric material extending laterally outwardly fromthe chassis and joined to the second portion of the liquid imperviousfilm; wherein the elastomeric material is a perforated film.